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NATIONAL MARITIME ACADEMY Introducing the: Wärtsilä RT- flex50

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Page 1: Sulzer Latest Engine

NATIONAL MARITIME ACADEMY

Introducing the:Wärtsilä RT-flex50

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RT-flex: Concept and benefitsRT-flex: Concept and benefits

The Wärtsilä RT-flex50 low-speed two-stroke marine diesel engine:

a) common-rail system for fuel injection.

b) common rail system for exhaust valve actuation, and

c) full electronic control of these engine functions

instead of the traditional mechanical camshaft system.

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Benefits:

Smokeless operation at all operating speeds

Lower steady running speeds, in the range of 10–15 per cent nominal speed, obtained smokelessly through sequential shut-off of injectors while continuing to run on all cylinders.

Reduced running costs through reduced part-load fuel consumption and longer times between overhauls

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Simpler setting of the engine. The ‘as-new’ running settings are automatically maintained.

Reduced maintenance costs through precise volumetric fuel injection control leading to extendable times between overhauls.

The common-rail system with its volumetric control gives excellent balance in engine power developed between cylinders and between cycles, with precise injection timing and equalised thermal loads

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Reliability is given by long-term testing of common-rail hardware in component test rigs.

Higher availability owing to the integrated monitoring functions.

High availability also given by the built-in redundancy, provided by the ample capacity and duplication in the supply pumps, main delivery pipes, crank-angle sensors, electronic control units and other key elements.

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At the At the heart of heart of the RT-the RT-

flex flex system system

are are quick-quick-actingactingSulzer Sulzer

Rail Rail ValvesValves

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Various RT-flex equipment on the half-platform of a Various RT-flex equipment on the half-platform of a 12RT-flex96C engine. From left to right, these include 12RT-flex96C engine. From left to right, these include (A) the local engine control panel, (B) the automatic fine (A) the local engine control panel, (B) the automatic fine filter for servo and control oil, (C) the two electrically-filter for servo and control oil, (C) the two electrically-driven control oil pumps and (D) the supply unit.driven control oil pumps and (D) the supply unit.

B

A

C

D

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RT-flex common-rail system RT-flex common-rail system

The common rail for fuel injection is a single-piece pipe running the length of the engine at just below the cylinder cover level.

The common rail and other related pipe work are arranged beneath the top engine platform and readily accessible from above.

The common rail is fed with heated fuel oil at the usual high pressure (nominally 1000 bar) ready for injection.

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The supply unit for the fuel has a number of high-pressure pumps actuated by cams driven through gearing from the crankshaft.

Fuel is delivered from this common rail through aseparate injection control unit (ICU), mounted directly on the rail, for each engine cylinder to the standard fuel injection valves which are operated in the usual way by the high-pressure fuel oil.

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Supply unit Supply unit of theof the

7RT-flex60C 7RT-flex60C with fuel with fuel

pumps on pumps on the rightthe rightand the and the servo oil servo oil

pumps on pumps on the leftthe left

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Close Close view of view of the fuel the fuel supply supply pumps pumps

showing showing the the

regulating regulating linkage.linkage.

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Using quick-acting Wärtsilä rail valves, they regulate the timing of fuel injection, control thevolume of fuel injected, and set the shape of the injection pattern.

Each ICU serves the two fuel injection valves in its corresponding cylinder cover. Each injection valve is separately controlled so that, although they normally act in unison, they can also be programmed to operateseparately as necessary.

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Injection control Injection control unit (ICU) for the unit (ICU) for the

three fuelthree fuelinjection valves of injection valves of one cylinder. Th e one cylinder. Th e dashed line marks dashed line marks

thetheseparation separation

between the between the control oil and the control oil and the

fuel oil sidesfuel oil sides..

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The exhaust valves are operated in the same way as in RTA engines by a hydraulic pushrod but actuating energy now comes from a servo oil rail at 200 bar pressure.

The servo oil is supplied by high-pressure hydraulic pumps incorporated in the supply unit with the fuel supply pumps. The electronically-controlled actuating unit for each cylinder gives full flexibility for setting the timing of valve opening and closing.

Exhaust Valve operationExhaust Valve operation

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Exhaust valve actuation andExhaust valve actuation andservo oil systemsservo oil systems

The Sulzer RT-flex system also includes The Sulzer RT-flex system also includes exhaust valve actuation and starting air exhaust valve actuation and starting air control. The exhaust valves are operated in control. The exhaust valves are operated in much the same way as in existing Sulzer much the same way as in existing Sulzer RTA engines with a hydraulic pushrod but RTA engines with a hydraulic pushrod but with the actuating energy now coming from with the actuating energy now coming from a servo oil rail at 200 bar pressure. The a servo oil rail at 200 bar pressure. The servo oil is supplied by high-pressure servo oil is supplied by high-pressure hydraulic pumps driven from the same gear hydraulic pumps driven from the same gear drive as the fuel pumps.drive as the fuel pumps.

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The electronically-controlled actuating unit for each cylinder gives full flexibility for valve opening and closing patterns. This unit utilises exactly the same rail valves as are used for controlling fuel injection.

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The exhaust valve The exhaust valve drive on top of the drive on top of the

exhaust valveexhaust valvespindle with the spindle with the

hydraulic cylinder and hydraulic cylinder and the air spring. Thethe air spring. The

two position sensors two position sensors (not visible in this view) (not visible in this view)

measure themeasure theradial distance to the radial distance to the cone to determine the cone to determine the

spindle’s verticalspindle’s verticalposition.position.

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The exhaust The exhaust valve valve

actuator with actuator with the large-the large-diameterdiameteractuator actuator piston on piston on

the left and the left and the hydraulic the hydraulic control slide control slide

ononthe right.the right.

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Page 23: Sulzer Latest Engine

Supply unit on a Supply unit on a Sulzer Sulzer

12RT-flex96C 12RT-flex96C engine with the engine with the fuel pumps infuel pumps ina Vee-form a Vee-form

arrangement on arrangement on the left and the left and

servo oil pumps servo oil pumps on the right-on the right-

hand face of thehand face of thecentral gear central gear

drive.drive.

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Inside a Size IV rail unit during assembly. The exhaustInside a Size IV rail unit during assembly. The exhaustvalve actuator (A) is mounted on the servo oil rail and valve actuator (A) is mounted on the servo oil rail and

the injection control unit (B) is on the fuel rail.the injection control unit (B) is on the fuel rail.Next to the fuel rail is the smaller control oil rail (C) and Next to the fuel rail is the smaller control oil rail (C) and

the return pipe for servo and control oil (D).the return pipe for servo and control oil (D).

A

B

CD

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All functions in the RT-flex system are controlled and monitored through the integrated Wärtsilä WECS-9520 electronic control system.

This is a modular system with a separate FCM-20 microprocessor control unit for each cylinder.

An additional FCM-20 unit provides all connections to other systems such as the remote control and alarm systems.

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Inside one of the electronicInside one of the electroniccontrol unitscontrol units

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Lower turbocharger efficiencies at part load normally result in low excess combustion air with fixed valve timing.Another important contribution to fuel economy of the RT-flex50 engines is the capability to adapt easily the injection timing to various fuel properties having a poor combustion behaviour.

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Three-dimensional drawing of the inside of a rail unit for anThree-dimensional drawing of the inside of a rail unit for anRT-fl ex96C engine, showing the fuel rail (A), the control oil rail (B) RT-fl ex96C engine, showing the fuel rail (A), the control oil rail (B) and the servo oil rail (C) with the control units for injection (D) and and the servo oil rail (C) with the control units for injection (D) and exhaust valve actuation (E) on top of their respective rails. Otherexhaust valve actuation (E) on top of their respective rails. Othermanifold pipes are provided for oil return, fuel leakage return, manifold pipes are provided for oil return, fuel leakage return, and the system oil supply for the exhaust valve drives.and the system oil supply for the exhaust valve drives.

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Electronic control unitsElectronic control unitsbeneath the front of the rail unitbeneath the front of the rail unitof a Sulzer RT-fl ex96C engine.of a Sulzer RT-fl ex96C engine.

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RT-flex: Cleaner in the environmentRT-flex: Cleaner in the environment

Exhaust gas emissions have become an Exhaust gas emissions have become an important aspect of marine diesel engines. All important aspect of marine diesel engines. All Wärtsilä RTA and RT-flex engines as standard Wärtsilä RTA and RT-flex engines as standard comply with the NOX emissions limit set by IMO comply with the NOX emissions limit set by IMO in Annex VI of the MARPOL 73/78 convention.in Annex VI of the MARPOL 73/78 convention.

RT-flex engines, however, come comfortably RT-flex engines, however, come comfortably below this NOX limit by virtue of their extremely below this NOX limit by virtue of their extremely wide flexibility in optimising the fuel injection wide flexibility in optimising the fuel injection and exhaustand exhaust

valve processes.valve processes.

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A visible benefit of RT-flex engines is their smokeless operation at all ship speeds.The superior combustion with the common-rail system is largely because the fuel injection pressure is maintained at the optimum level irrespective of engine speed. At very low speeds, individual fuel injectors are selectively shut off and the exhaust valve timing adapted to help to keep smoke emissions below the visible limit.

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Engine structureEngine structure

A high structural rigidity is of major importance for the today’s two-stroke engine’s long stroke. The design is based on stress and deformation calculations carried out by using a full three-dimensional finite-element computer model for different column designs to verify the optimum frame configuration.

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A ‘gondola’-type bedplate surmounted by very rigid, A-shaped double-walled columns and cylinder block, all secured by pre-tensioned vertical tie rods.The whole structure is very sturdy with low stresses and high stiffness. Both bedplate and columns are welded fabrications which are also designed for minimum machining.

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Lowering the Lowering the crankshaft into crankshaft into the bedplate,the bedplate,

6 RT Flex - 506 RT Flex - 50

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side is normally from the supply unit side, side is normally from the supply unit side, but is also possible from the receiver side but is also possible from the receiver side of the engine, to allow for maintenance of of the engine, to allow for maintenance of the piston rod gland and also for the piston rod gland and also for inspecting piston rings.inspecting piston rings.

The cylinder jacket is a single-piece cast-The cylinder jacket is a single-piece cast-iron cylinder block with a high rigidity. The iron cylinder block with a high rigidity. The cylinder liners are seated in the cylinder cylinder liners are seated in the cylinder block, and are sufficiently robust to carry block, and are sufficiently robust to carry the cylinder covers without requiring a the cylinder covers without requiring a support ring. A lightsupport ring. A light

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sleeve is applied to upper part of each liner to form a water jacket.The tilting-pad thrust bearing is integrated in the bedplate. Owing to the use of gear wheels for the supply unit drive, the thrust bearing can be very short and very stiff, and can be carried in a closed, rigid housing.

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Main Bearing Housing in bed plateMain Bearing Housing in bed plate

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Running gearRunning gearThe running gear comprises the crankshaft,The running gear comprises the crankshaft,connecting rods, pistons and piston rods,connecting rods, pistons and piston rods,together with their associated bearings and together with their associated bearings and piston rod glands.piston rod glands.The crankshaft is semi-built comprising The crankshaft is semi-built comprising combined crank pin/web elements forged combined crank pin/web elements forged from a solid ingot and the journal pins are from a solid ingot and the journal pins are then shrunk into the crank webs.then shrunk into the crank webs.The main bearings have white metal shells. The main bearings have white metal shells. Each main bearing cap is held down by four Each main bearing cap is held down by four elastic holding down studs.elastic holding down studs.

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A better understanding of the main bearing loads is obtained with today’s finite-element analysis and elastohydrodynamic calculation techniques as they take into account the structure around the bearing and vibration of the shaft. The FE model comprises the complete shaft and its bearings together with the surrounding structure.Boundary conditions, including the crankshaft stiffness, can thus be fed into the bearing calculation.

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The crosshead bearing is designed to the same principles as for all other RTA and RT-flex engines. It also features a full-width lower half bearing with the crosshead pin being of uniform diameter. The crosshead bearings have thin-walled shells of white metal for a high load bearing capacity

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Crosshead (l) and Piston Rod Crosshead (l) and Piston Rod Gland (r)Gland (r)

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Extensive development work has been put into Extensive development work has been put into The piston rod gland because of its importance in The piston rod gland because of its importance in Keeping crankcase oil consumption down to a Keeping crankcase oil consumption down to a reasonable level and maintaining the quality of reasonable level and maintaining the quality of the system oil.the system oil.The piston rod glands are of an improved designThe piston rod glands are of an improved designwith highly-effective dirt scraping action in the top with highly-effective dirt scraping action in the top Part and system oil scraping in the lower part. Part and system oil scraping in the lower part. The glands are provided with large drain areas The glands are provided with large drain areas and channels. Losses of system oil are minimised and channels. Losses of system oil are minimised as all scraped-off oil is recirculated internally to as all scraped-off oil is recirculated internally to the crankcase. Hardened piston rods are nowthe crankcase. Hardened piston rods are nowstandard to ensure long-term stability in the gland standard to ensure long-term stability in the gland

behaviour.behaviour.1212

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• Crosshead Crosshead and and

connecting rodconnecting rod

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Combustion chamberCombustion chamber

The combustion chamber in today’s diesel engine has a major influence on the engine’s reliability. Careful attention is needed for the layout of the fuel injection spray pattern to achieve moderate surface temperatures and to avoid carbon deposits.At Wärtsilä, optimisation of fuel injection is carried out first by the use of modern calculation tools, such as CFD(computerised fluid dynamics) analysis.

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The calculated results are then confirmed on the first test engines.The well-proven bore-cooling principle is also employed in the cylinder cover, exhaust valve seat and piston crown to control their temperatures, as well as thermal strainsand mechanical stresses. The surface temperatures of the cylinder liner are optimised for good piston-running behaviour, without requiring bore cooling of the liner.

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The solid forged steel, bore-cooled cylinder coveris secured by eight elastic studs. It is equipped with asingle, central exhaust valve in Nimonic alloy whichis housed in a bolted-on valve cage. Two fuel injectionvalves are symmetrically arranged in each cylinder cover.

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Anti-corrosion cladding is applied to the cylinder covers downstream of the injection nozzles to protect the cylinder covers from hot corrosive or erosive attack.The pistons comprise a forged steel crown with a short skirt. Combined jet-shaker oil cooling of the piston crown provides optimum cooling performance. It gives very moderate temperatures on the piston crown with an even temperature distribution right across the crown surface.

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Piston-running behaviourPiston-running behaviour

Today the time between overhaul (TBO) of Today the time between overhaul (TBO) of low-speed marine diesel engines is largely low-speed marine diesel engines is largely determined by the piston-running behaviour determined by the piston-running behaviour and its effect on the wear of piston rings and and its effect on the wear of piston rings and cylinder liners. For this reason, Wärtsilä RT-cylinder liners. For this reason, Wärtsilä RT-flex50 engines now incorporate a packageflex50 engines now incorporate a packageof design measures that enable the TBO of of design measures that enable the TBO of the cylinder components, including piston the cylinder components, including piston ring renewal, to be extended to at least three ring renewal, to be extended to at least three years, while allowing the further reduction of years, while allowing the further reduction of cylinder lubricating oil feed ratecylinder lubricating oil feed rate

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Design measures applied to improve piston-Design measures applied to improve piston-running behaviour include:running behaviour include: Liner of the appropriate materialLiner of the appropriate material Careful turning of the liner running surface and plateau Careful turning of the liner running surface and plateau

honing of the liner over the full length of the running honing of the liner over the full length of the running surfacesurface

Mid-stroke liner insulationMid-stroke liner insulation Pre-profiled piston rings in all piston groovesPre-profiled piston rings in all piston grooves Chromium-ceramic coated, pre-profiled gas-tight piston Chromium-ceramic coated, pre-profiled gas-tight piston

ring in the top piston ring groovering in the top piston ring groove RC (Running-in Coating) piston rings in all lower piston RC (Running-in Coating) piston rings in all lower piston

groovesgrooves Anti-Polishing Ring (APR) at the top of the cylinder linerAnti-Polishing Ring (APR) at the top of the cylinder liner Increased thickness of chromium layer in the piston ring Increased thickness of chromium layer in the piston ring

grooves.grooves. Wärtsilä accumulatorWärtsilä accumulator system for cyl. lubrication. system for cyl. lubrication.

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Installation arrangementsInstallation arrangements that help to facilitate shipboard installation.that help to facilitate shipboard installation. The engine layout fields give the ship designer ampleThe engine layout fields give the ship designer ample freedom to match the engine to the optimum propeller forfreedom to match the engine to the optimum propeller for the ship.the ship. The engines have simple seating arrangements with aThe engines have simple seating arrangements with a modest number of holding down bolts and side stoppers.modest number of holding down bolts and side stoppers. No end stoppers or thrust brackets are needed as thrustNo end stoppers or thrust brackets are needed as thrust transmission is provided by fitted bolts or thrust sleevestransmission is provided by fitted bolts or thrust sleeves which are applied to a number of the holding-down bolts.which are applied to a number of the holding-down bolts. The holes in the tank top for the thrust sleeves can beThe holes in the tank top for the thrust sleeves can be made by drilling or even flame cutting. After alignmentmade by drilling or even flame cutting. After alignment of the bedplate, epoxy resin chocking material is pouredof the bedplate, epoxy resin chocking material is poured around the thrust sleeves.around the thrust sleeves.

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All ancillaries, such as pumps and tank capacities, andAll ancillaries, such as pumps and tank capacities, and their arrangement are optimised to reduce the installationtheir arrangement are optimised to reduce the installation and operating costs. The number of pipe connections onand operating costs. The number of pipe connections on the engine that must be connected by the shipyard arethe engine that must be connected by the shipyard are minimised. The engine’s electrical power requirement forminimised. The engine’s electrical power requirement for the ancillary services is also kept down to a minimum.the ancillary services is also kept down to a minimum. A standard all-electric interface is employed for engineA standard all-electric interface is employed for engine management systems – known as DENIS (Diesel Enginemanagement systems – known as DENIS (Diesel Engine Interface Specification) – to meet all needs for control,Interface Specification) – to meet all needs for control, monitoring, safety and alarm warning functions. Thismonitoring, safety and alarm warning functions. This matches remote control systems and ship control systemsmatches remote control systems and ship control systems from a number of approved suppliers.from a number of approved suppliers. The engine is equipped with an integrated axialThe engine is equipped with an integrated axial detuner at the free end of the crankshaft. An axial detunerdetuner at the free end of the crankshaft. An axial detuner monitoring system developed by Wärtsilä is optionalmonitoring system developed by Wärtsilä is optional equipment for the RT-flex50 engine.equipment for the RT-flex50 engine.

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A key element is the deep-honed liner. Careful machiningand deep honing gives the liner an ideal running surfacefor the piston rings, together with an optimum surfacemicrostructure.The Anti-Polishing Ring prevents the build up ofdeposits on the top land of the piston which can damagethe oil film on the liner and cause bore polishing.It is also important that the liner wall temperature isoptimised to keep the liner surface above the dew pointtemperature throughout the piston stroke to avoid coldcorrosion. At the same time, the ‘underslung’ scavenge airreceiver and the highly-efficient vane-type water separatorswith effective water drainage arrangements ensure that asmuch water as possible is taken out of the scavenge air.

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Load-dependent cylinder lubrication is provided bythe well-proven Wärtsilä accumulator system whichprovides the timely quantity of lubricating oil for goodpiston-running. The lubricating oil feed rate is controlledaccording to the engine load and can also be adjustedaccording to engine condition. The system allows feedrates down to 1.1 g/kWh for engine loads of 50–100%and all fuel sulphur contents above 1.5%, though a feedrate of 0.9 g/kWh is possible after analysis of engineperformance.

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Turbocharging andTurbocharging andscavenge air systemscavenge air system

The RT-flex50 engines are uniflow scavenged with airinlet ports in the lower part of the cylinder and a single,central exhaust valve in the cylinder cover. Scavengeair is delivered by a constant-pressure turbochargingsystem with one or more high-efficiency exhaust gas

turbochargers depending on the numbers of cylinders. For

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starting and during slow-running, the scavenge air delivery is augmented by electrically-driven auxiliary blowers.The scavenge air receiver is of an underslung design with integral non-return flaps, air cooler, water separator and the auxiliary blowers. The turbochargers are mounted on the scavenge air receiver which also carries the supportfor the exhaust manifold.

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Immediately after the horizontal air cooler, the scavenge air is swung round 180 degrees to the engine cylinders, in the process passing through the vertically-arranged water separator. The highly-efficient water separator comprises a row of vanes which divert the air flow and collect the water. There are ample drainage provisions to remove completely the condensed water collected at the bottom of the separator. This arrangement provides the effective separation of condensed water from the stream of scavenge air which is imperative for satisfactory piston-running behaviour.

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Installation arrangementsInstallation arrangements

Specific design features help to facilitate shipboard Specific design features help to facilitate shipboard installation.installation.

The engine layout fields give the ship designer The engine layout fields give the ship designer ample freedom to match the engine to the ample freedom to match the engine to the optimum propeller for the ship.optimum propeller for the ship.

The engines have simple seating arrangements The engines have simple seating arrangements with a modest number of holding down bolts and with a modest number of holding down bolts and side stoppers. No end stoppers or thrust brackets side stoppers. No end stoppers or thrust brackets are needed as thrust transmission is provided by are needed as thrust transmission is provided by fitted bolts or thrust sleeves which are applied to a fitted bolts or thrust sleeves which are applied to a number of the holding-down bolts.number of the holding-down bolts.

The holes in the tank top for the thrust sleeves The holes in the tank top for the thrust sleeves can be made by drilling or even flame cutting. can be made by drilling or even flame cutting. After alignment of the bedplate, epoxy resin After alignment of the bedplate, epoxy resin chocking material is poured around the thrust chocking material is poured around the thrust sleeves.sleeves.

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All ancillaries, such as pumps and tank capacities, andtheir arrangement are optimised to reduce the installation and operating costs. The number of pipe connections on the engine that must be connected by the shipyard are minimised. The engine’s electrical power requirement for the ancillary services is also kept down to a minimum.A standard all-electric interface is employed for enginemanagement systems – known as DENIS (Diesel Engine Interface Specification) – to meet all needs for control, monitoring, safety and alarm warning functions. This matches remote control systems and ship control systemsfrom a number of approved suppliers.

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The engine is equipped with an integrated axialThe engine is equipped with an integrated axialdetuner at the free end of the crankshaft. An axial detuner at the free end of the crankshaft. An axial detuner monitoring system developed by detuner monitoring system developed by WärtsiläWärtsilä is is

optional equipment for the RT-flex50 engine.optional equipment for the RT-flex50 engine. starting and during slow-running, the scavenge starting and during slow-running, the scavenge

air delivery is augmented by electrically-driven air delivery is augmented by electrically-driven auxiliary blowers.auxiliary blowers.

The scavenge air receiver is of an underslung The scavenge air receiver is of an underslung designwith integral non-return flaps, air cooler, designwith integral non-return flaps, air cooler, water separator and the auxiliary blowers. The water separator and the auxiliary blowers. The turbochargers are mounted on the scavenge air turbochargers are mounted on the scavenge air receiver which also carries the support for the receiver which also carries the support for the exhaust manifold.exhaust manifold.

Immediately after the horizontal air cooler, the Immediately after the horizontal air cooler, the scavenge air is swung round 180 degrees to the scavenge air is swung round 180 degrees to the engine cylinders, in the process passing through engine cylinders, in the process passing through the vertically-arranged water separator. the vertically-arranged water separator.

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The highly-efficient water separator comprisesThe highly-efficient water separator comprises a row of vanes which divert the air flow and collect thea row of vanes which divert the air flow and collect the water. There are ample drainage provisions to removewater. There are ample drainage provisions to remove completely the condensed water collected at the bottomcompletely the condensed water collected at the bottom of the separator. This arrangement provides the effectiveof the separator. This arrangement provides the effective separation of condensed water from the stream of separation of condensed water from the stream of

scavengescavenge air which is imperative for satisfactory piston-runningair which is imperative for satisfactory piston-running behaviour behaviour

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MaintenanceMaintenance

Two of the primary objectives in the Two of the primary objectives in the design and development of Wärtsilä design and development of Wärtsilä low-speed engines that havelow-speed engines that have

beneficial effects on maintenance beneficial effects on maintenance requirements are high reliability and requirements are high reliability and long times between overhauls. long times between overhauls. Three years between overhauls are Three years between overhauls are now being achieved by engines tonow being achieved by engines to

the latest design standards. At the the latest design standards. At the same time, their high reliability gives same time, their high reliability gives shipowners more freedom to shipowners more freedom to arrange maintenance work within arrange maintenance work within ships’ sailing schedules.ships’ sailing schedules.

Yet, as maintenance work is Yet, as maintenance work is inevitable, particular attention is inevitable, particular attention is given to ease of maintenance by given to ease of maintenance by including tooling and easy access, including tooling and easy access, and by providing easy-to-and by providing easy-to-understand instructions.understand instructions.

All major fastenings throughout the All major fastenings throughout the engine are tightened by hydraulic engine are tightened by hydraulic jacks. For the RT-flex50, the jacks. For the RT-flex50, the dimensions and weights of the jacks dimensions and weights of the jacks are kept low by the use of 1500 bar are kept low by the use of 1500 bar working pressure. Access to the working pressure. Access to the crankcase continues to be possible crankcase continues to be possible from both sides of the engine. The from both sides of the engine. The handling of components within the handling of components within the crankcase is facilitated by amplecrankcase is facilitated by ample

provision for hanging hoisting provision for hanging hoisting equipment. The Wärtsilä RT-flex equipment. The Wärtsilä RT-flex system is designed to be usersystem is designed to be user

friendly, without requiring ships’ friendly, without requiring ships’ engineers to have any special engineers to have any special additional skills. The system additional skills. The system incorporates its own diagnostic incorporates its own diagnostic functions, and all the critical elements functions, and all the critical elements are made for straightforward are made for straightforward replacementreplacement

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Main technical dataMain technical data

All dimensions are in millimetres.All dimensions are in millimetres. The engine weight is net in metric The engine weight is net in metric

tonnes (t), without oil and water.tonnes (t), without oil and water. R1, R2, R3, R4 = power/speed R1, R2, R3, R4 = power/speed

ratings at the four corners of the ratings at the four corners of the engine layout field (see diagram).engine layout field (see diagram).

R1 = engine Maximum R1 = engine Maximum Continuous Rating (MCR).Continuous Rating (MCR).

Contract-MCR (CMCR) = Contract-MCR (CMCR) = selected rating point for particular selected rating point for particular installation. Any CMCR point can installation. Any CMCR point can bebe

selected within the engine layout selected within the engine layout field.field.

BSFC = brake specific fuel BSFC = brake specific fuel consumptions (BSFC). All figures consumptions (BSFC). All figures are quoted for fuel of lower are quoted for fuel of lower calorific value 42.7 MJ/kg, and for calorific value 42.7 MJ/kg, and for ISO standard reference ISO standard reference conditions (ISOconditions (ISO

15550 and 3046). The BSFC 15550 and 3046). The BSFC figures are given with a tolerance figures are given with a tolerance of +5%.of +5%.

The values of power in kilowatts The values of power in kilowatts and fuel consumption in g/kWh and fuel consumption in g/kWh are the standard figures.are the standard figures.

ISO standard reference conditionsISO standard reference conditions Total barometric pressure at Total barometric pressure at

R1 .......................... 1.0 barR1 .......................... 1.0 bar Suction air Suction air

temperature ..................................temperature ........................................ 25 °C...... 25 °C

Relative Relative humidity .........................................humidity ...................................................30%..........30%

Scavenge air cooling water Scavenge air cooling water temperature:temperature:

– – with sea with sea water .............................................water ..................................................25 °C.....25 °C

– – with fresh with fresh water .............................................water ................................................. 29 °C.... 29 °C

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Key elements of theKey elements of theSulzer RT-flexSulzer RT-flex

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World’s biggest common railWorld’s biggest common rail

The Sulzer RT-flex concept brings common-railThe Sulzer RT-flex concept brings common-rail fuel injection to the modern, large diesel engine.fuel injection to the modern, large diesel engine. Current jerk-type fuel injection systemsCurrent jerk-type fuel injection systems combine pressure generation, timing andcombine pressure generation, timing and metering in the injection pump with only limitedmetering in the injection pump with only limited flexibility to influence the variables. In contrast,flexibility to influence the variables. In contrast, the common-rail system separates thethe common-rail system separates the functions and gives far more flexibility. It has thefunctions and gives far more flexibility. It has the distinctive features of precise volumetric fueldistinctive features of precise volumetric fuel injection control, variable injection rate shaping,injection control, variable injection rate shaping, and free selection of injection pressure.and free selection of injection pressure.

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Well-proven fuel pumpsWell-proven fuel pumps

It employs high-efficiency fuel pumps based onIt employs high-efficiency fuel pumps based on the well-proven design of injection pumps usedthe well-proven design of injection pumps used in Sulzer medium-speed engines. They run onin Sulzer medium-speed engines. They run on multi-lobe cams to deliver adequate quantitiesmulti-lobe cams to deliver adequate quantities of fuel to the common rail at the usual highof fuel to the common rail at the usual high pressure ready for injection. The common railpressure ready for injection. The common rail is, in effect, a manifold running the length of theis, in effect, a manifold running the length of the engine just below the cylinder cover level. Itengine just below the cylinder cover level. It provides a certain storage volume for the fuelprovides a certain storage volume for the fuel oil, and has provision for damping dynamicoil, and has provision for damping dynamic pressure wavepressure wave

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Electronic injection controlElectronic injection control Fuel is delivered from the common rail throughFuel is delivered from the common rail through injection control units to standard fuel injectioninjection control units to standard fuel injection valves. The control unit for each engine cylindervalves. The control unit for each engine cylinder regulates the timing of fuel injection, providesregulates the timing of fuel injection, provides control of the volume of fuel injected, and setscontrol of the volume of fuel injected, and sets the shape of the injection pattern. The threethe shape of the injection pattern. The three fuel injection valves in the respective cylinderfuel injection valves in the respective cylinder cover are independently controlled so that theycover are independently controlled so that they may be programmed to operate separately ormay be programmed to operate separately or in unison as necessary.in unison as necessary.

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Ideal for heavy fuel oilIdeal for heavy fuel oil

Sulzer RT-flex system is purpose-built forSulzer RT-flex system is purpose-built for

operation on standard grades of heavy fuel operation on standard grades of heavy fuel

oil.oil.

For this reason, it incorporates certain For this reason, it incorporates certain

design features not seen in other common-design features not seen in other common-

rail engines using middle-distillate diesel rail engines using middle-distillate diesel

oils.oils.

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Ease of installationEase of installation

Although RT-flex engines can be calledAlthough RT-flex engines can be calledrevolutionary, they are fully compatible withrevolutionary, they are fully compatible withthe RTA engines in relation to engine roomthe RTA engines in relation to engine roominstallation and shipboard operation. Thisinstallation and shipboard operation. Thismeans that the main outline dimensions,means that the main outline dimensions,foundations, key engine parameters, foundations, key engine parameters, integration in ship automation and otherintegration in ship automation and otherinterfaces of the RT-flex engines are interfaces of the RT-flex engines are identical with those of the corresponding identical with those of the corresponding RTA engines.RTA engines.

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It should also be noted that at heart theRT-flex engines have the same structure,running gear and processes as the existingRTA-series engines. In addition, vital partssuch as the fuel injectors and exhaust valves of the RT-flex are fully compatible with those of RTA engines.

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Typical injection pattern of Typical injection pattern of Sulzer RT-flex enginesSulzer RT-flex engines

with all injection nozzles acting with all injection nozzles acting in unison showing needlein unison showing needle

lift, fuel rail pressure, injection lift, fuel rail pressure, injection pressure and cylinder pressurepressure and cylinder pressure

when all injection nozzles are when all injection nozzles are operating simultaneously.operating simultaneously.

Note the sharp beginning and Note the sharp beginning and ending of injection, the lackending of injection, the lack

of a significant pressure drop of a significant pressure drop in the common rail duringin the common rail during

injection, and the small rail injection, and the small rail pressure fluctuations.pressure fluctuations.

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Sulzer RT-fl ex engines have the unique ability toSulzer RT-fl ex engines have the unique ability toshut off individual fuel injectors, here shown schematically.shut off individual fuel injectors, here shown schematically.

This feature is used to assure clean combustion for This feature is used to assure clean combustion for smokeless,smokeless,

stable running at very low speeds.stable running at very low speeds.

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Th e world’s most powerful common-rail engine, the Sulzer Th e world’s most powerful common-rail engine, the Sulzer 12RT-fl ex96C engine develops 68,640 kW at 102 rpm, and12RT-fl ex96C engine develops 68,640 kW at 102 rpm, and

measures about 24 m long by 13.5 m high.measures about 24 m long by 13.5 m high.